Duplex Stainless Steel E2209-16 Welding Electrode Supplier in Mumbai, India
Nicorex Alloys is a trusted stockist and supplier of E2209-16 duplex stainless steel welding electrodes, based in Mumbai, India. The weld deposit contains approximately 23% Chromium, 9.5% Nickel, 3.2% Molybdenum, and 0.17% Nitrogen. This chemistry yields a Pitting Resistance Equivalent Number (PREN) of 35 or above.
E2209-16 is a duplex stainless steel electrode that produces a weld with a balanced austenite-ferrite structure. This gives high resistance to chloride stress corrosion cracking, where many standard austenitic stainless electrodes fail. It is classified as AWS A5.4 / ASME SFA 5.4, UNS W39209, and is a rutile-coated electrode for SMAW of 22Cr duplex stainless steels. The weld metal offers at least 690 MPa (100 ksi) tensile strength, about 87 ksi yield strength, a minimum 20% elongation, and Charpy impact toughness down to -60°C. A controlled ferrite number (FN 25-55) ensures good corrosion resistance and strength without sigma phase problems up to 250°C. Diameters: 2.4, 3.2, 4.0, and 4.8 mm. All positions are possible up to 4.0 mm; 4.8 mm is for flat and horizontal only. It can run on DCEP or AC.
Primary base metals joined include UNS S31803/S32205 (2205 duplex), S32304 (lean duplex 2304), and dissimilar joints to carbon steel or austenitic stainless steel. The coated electrode complies with AWS A5.4, ASME SFA 5.4, and EN ISO 3581-A (E 22 9 3 N L R 1 2). Key industries served: offshore oil and gas, chemical processing, desalination, pulp and paper, and marine infrastructure. Nicorex Alloys is ISO 9001 and ISO 14001 certified. Every batch ships with MTC 3.1 per EN 10204 and all-weld-metal test reports.
E2209-16 Coated Electrode Specifications & Standards
| AWS Classification | E2209-16 |
|---|---|
| ASME SFA Specification | SFA 5.4EN ISO 3581 |
| UNS Number | W39209 |
| Welding Process | SMAW (Shielded Metal Arc Welding) |
| Electrode Coating Type | Rutile (TiO₂-based) |
| Current / Polarity | DCEP or AC (min 70V OCV for AC) |
| Welding Positions | All positions (F, V, OH, H); 4.8 mm flat & horizontal only |
| Available Diameters | 2.4, 3.2, 4.0, 4.8 mm (3/32″, 1/8″, 5/32″, 3/16″) |
| Electrode Length | 300-350 mm (12″-14″) |
What Does E2209-16 Mean? — AWS Classification Breakdown
| Symbol | Meaning |
|---|---|
| E | Electrode, designed for electric arc welding (SMAW process) |
| 22 | Nominal 22% chromium content in the weld deposit |
| 09 | Nominal 9% nickel content in the weld deposit |
| -16 | Rutile (TiO₂-based) coating; AC or DCEP, all-position capable, smooth arc, easy slag removal |
Three coating suffix variants exist for the 2209 duplex SMAW electrode. The “-15” suffix indicates a basic (CaF₂) coating restricted to DCEP only, offering superior low-temperature Charpy toughness. The “-16” suffix denotes a rutile coating compatible with AC or DCEP, providing better arc stability and operator appeal. A “-17” suffix, used by some manufacturers, identifies a rutile-silicate coating with improved wetting and bead appearance.
All three coating variants deposit identical weld metal chemistry per AWS A5.4. The difference lies in welding operability, arc characteristics, and slag behaviour, not in the deposited metal composition. The “2209” portion refers to the nominal composition of the weld deposit (22Cr-9Ni), not the electrode wire or core.
Chemical Composition of E2209-16 Weld Deposit (%)
| Element | Carbon (C) | Chromium (Cr) | Nickel (Ni) | Molybdenum (Mo) | Nitrogen (N) | Manganese (Mn) | Silicon (Si) | Copper (Cu) | Phosphorus (P) | Sulfur (S) | Iron (Fe) |
|---|---|---|---|---|---|---|---|---|---|---|---|
| Specification Range (wt%) | 0.04 max | 21.5-23.5 | 8.5-10.5 | 2.5-3.5 | 0.08-0.20 | 0.5-2.0 | 1.00 max | 0.75 max | 0.04 max | 0.03 max | Balance |
| Typical Deposit | 0.03 | 23.0 | 9.6 | 3.2 | 0.17 | 1.2 | 0.67 | 0.08 | 0.02 | 0.002 | Balance |
The 22% Cr, 3% Mo, and nitrogen content yield a PREN (≥35), calculated as %Cr + 3.3×%Mo + 16×%N. Nitrogen at 0.08-0.20% stabilises the austenite phase and prevents excessive ferrite formation in the heat-affected zone. Low carbon (≤0.04%) minimises carbide precipitation risk at grain boundaries during multi-pass welding.
Actual weld deposit chemistry depends on welding parameters, dilution from base metal, and shielding conditions.
All-Weld-Metal Mechanical Properties of E2209-16
| Property | Ultimate Tensile Strength | Yield Strength (0.2% offset) | Elongation | Charpy Impact (+20°C) | Charpy Impact (-20°C) | Charpy Impact (-40°C) | Charpy Impact (-60°C) | Hardness | Ferrite Number (FN) |
|---|---|---|---|---|---|---|---|---|---|
| AWS A5.4 Minimum | 690 MPa (100 ksi) | — | 20% | — | — | — | — | — | — |
| Typical Values | 750 MPa (109 ksi) | 600 MPa (87 ksi) | 25-28% | 100 J | 85 J | 75 J | 65 J | ~28 HRC max | 25-55 (as-welded) |
The duplex microstructure provides roughly double the yield strength of ER308L or ER316L austenitic weld deposits. Charpy impact values at -60°C confirm suitability for cold-climate offshore and cryogenic-adjacent applications. The ferrite number should be verified per the WRC-1992 diagram or magnetic measurement on qualification test coupons.
Base Metal Compatibility & ASME P-Number Matrix for E2209-16
| Base Metal | UNS | ASTM Designation | ASME P-Number |
|---|---|---|---|
| 2205 Duplex | S31803 / S32205 | A240, A789, A790 | P-10H Group 1 |
| Lean Duplex 2304 | S32304 | A240, A789 | P-10H Group 1 |
| Lean Duplex 2101 | S32101 | A240 | P-10H Group 1 |
| Joint Combination | Recommended Use |
|---|---|
| Duplex 2205 to Carbon Steel (P-1) | Transition joints in piping and vessels |
| Duplex 2205 to 316L Austenitic (P-8) | Process piping tie-ins |
| Duplex 2304 to Duplex 2205 | Mixed-grade duplex fabrication |
Recommended Welding Parameters for E2209-16 Electrode
| Diameter (mm/in) | Flat (A) | V/OH (A) | Voltage (V) | Polarity |
|---|---|---|---|---|
| 2.4 mm (3/32″) | 70-90 | 65-80 | 20-23 | DCEP or AC |
| 3.2 mm (1/8″) | 80-110 | 80-100 | 21-24 | DCEP or AC |
| 4.0 mm (5/32″) | 120-160 | 100-120 | 22-25 | DCEP or AC |
| 4.8 mm (3/16″) | 155-210 | Flat/H only | 23-26 | DCEP or AC |
- Preheat: generally not required for duplex stainless steels.
- Maximum interpass temperature: 150°C (300°F); exceeding this risks sigma phase formation.
- Recommended heat input: 0.5-2.5 kJ/mm (10-30 kJ/in). Too low causes excessive ferrite; too high promotes sigma and chi phases.
- Maintain short arc length to minimise nitrogen loss from the weld pool.
- Stringer beads preferred. Limit weave width to 3× electrode diameter.
- PWHT is generally not required and may be detrimental to duplex microstructure. If mandated by code, solution anneal at 1050-1100°C followed by rapid water quench.
Get AWS Class E2209-16 Duplex Electrode at Competitive Prices
Industrial Welding Applications of E2209-16 Duplex Electrode
- Offshore Oil & Gas Platforms: Used for manual welds on 2205 duplex topside seawater cooling and firewater pipes, sour service wells, subsea tie-ins, and marine‑exposed structural parts that must meet NACE MR0175.
- Chemical & Petrochemical Processing: Used on reactor vessels and tubesheet‑to‑shell welds in chloride‑rich services, offering higher PREN than 316L to stop pitting in warm acetic, phosphoric, and caustic solutions.
- Desalination & Water Treatment: Chosen for reverse osmosis high‑pressure piping, evaporator tube joints, and brine lines because it resists warm seawater chlorides very well.
- Pulp & Paper Industry: Used for 2205 digestor vessels, bleach plant piping in ClO₂/hypochlorite service, and white liquor recovery boiler parts that need longer life than 316L.
- Marine & Shipbuilding: Used for ballast tank piping, structural welds, and propeller shaft brackets where class‑approved duplex welding is required.
- Food, Beverage & Pharmaceutical: Provides higher‑strength hygienic welds in duplex brewery/dairy lines and pharmaceutical reactors while meeting food‑contact standards after passivation.
Storage, Handling & Re-Drying of E2209-16 Stick Electrodes
- Store sealed electrodes in original hermetically sealed cans at 15-25°C. Relative humidity must stay below 50%.
- Once opened, transfer electrodes to a heated holding oven at 100-150°C.
- Re-bake rutile-coated E2209-16 at 300-350°C for 1-2 hours if moisture absorption is suspected. Basic-coated E2209-15 requires 350-400°C for 1 hour.
- Maximum two re-baking cycles. Beyond this, discard and replace.
- Maximum exposure: 4 hours outside the oven in ambient conditions. Reduce to 2 hours in environments above 60% RH.
Nicorex Alloys supplies hermetically sealed metal cans (2.5 kg, 5.0 kg) and vacuum-sealed cartons for export. For ER2209 matching TIG/MIG wire, store spools in sealed plastic bags with desiccant.
How to Order E2209-16 Welding Rod from Nicorex Alloys
- AWS Classification - E2209-16 per AWS A5.4 / ASME SFA-5.4
- Diameter - 2.4 mm / 3.2 mm / 4.0 mm / 4.8 mm
- Quantity - Specify kg or number of canisters
- Packaging - Hermetically sealed canisters; vacuum-sealed option available
- Testing / Certification - MTC EN 10204 3.1/3.2; FN Report; NACE MR0175
- Base Metal - Specify UNS S31803 / S32205 or dissimilar joint
- Third-Party Approvals - DNV / ABS / BV / LR / TÜV — specify
- Material Grade - Duplex 2209; UNS S39209; W.Nr. 1.4462
- Applicable Code - ASME VIII, IX, B31.3 — specify
- Delivery - Domestic / International — specify port or address
Request ER2209 GTAW filler rod and ER2209 GMAW wire alongside E2209-16 electrodes for multi-process WPS qualification. Standard stock items are dispatched within 2-5 business days from Mumbai.